Multi-response optimisation of machining parameters in WEDM using hybrid desirability-based TOPSIS concept

The present study is aimed to find the optimum parameters combination, which influences the wire electrode discharge machining (WEDM) process during machining through the use of a hybrid optimisation technique, desirability-based technique for order of preference by similarity to ideal solution (TOPSIS). It is a new, fast and relatively simple method used for the optimisation of material removal rate (MRR) and kerf-width simultaneously. The results recorded a 13.78% of overall improvement in the machining performance, which may use as a benchmarking for this process. The R2 and adj. R2 values obtained from the analysis of variance (ANOVA) i.e., 87.74% and 80.07% respectively concludes the greatest adequacy of the model. Microstructural analysis of wire electrode shows that the formation of few cracks due to interaction of the sparks and the ultrasonic vibrational waves during the high-speed movement of wire electrode, resulting in improved circulation of the dielectric medium, thereby speeding up the ejection of the melted material from the workpiece.